Decorative decal assembly for a weight plate

ABSTRACT

The decorative decal assembly ( 20 ) is configured to be secured within a recessed surface ( 26 ) of a weight plate ( 18 ) and includes an adhesive layer ( 36 ), a printable surface ( 44 ) of an adjacent ink protective printing layer ( 42 ), and one or more print decals ( 48 ) secured to the printable surface ( 44 ) and between an upper support surface ( 40 ) of the adhesive layer ( 36 ) and the ink protective layer ( 42 ). The recessed surface ( 26 ) defines a display area ( 56 ) surrounded on all sides by an expansion zone ( 58 ) extending between the display area ( 56 ) and the shoulders ( 30, 32 ) of the weight plate ( 18 ) that define the recessed surface ( 26 ) to permit limited expansion of perimeter edges ( 62 A,  62 B) of the decal assembly ( 20 ) into the expansion zone ( 58 ) without contacting the shoulders ( 30, 32 ) whenever the weight plate ( 18 ) experiences a bounce shock.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of U.S. patent applicationSer. No. 14/790,677, filed Jul. 2, 2015, now U.S. Pat. No. 10,046,954,which claims the benefit of U.S. Provisional Patent Application No.62/020,606, filed Jul. 3, 2014, which applications are hereinincorporated by reference in their entirety.

FIELD

This disclosure relates to a decorative decal for weight plates used inresistance training, weight lifting, etc., and especially relates to adecorative decal assembly for application within a recessed surface of aweight plate.

BACKGROUND

It is well known that weight plates receive applications of trademarks,logos and other indicia of marketing value and for purposes ofindicating the load of the plate as well as indicating special events.Known, modern weight plates are being used such as in Olympiccompetition or “CROSSFIT” training. (“CROSSFIT” is a registeredtrademark of CrossFit, Inc., a Delaware Corporation.) It is increasinglycommon that standardized weight plates are utilized in such competitionand fitness training. The standardized plates are almost invariablycircular and they typically are made of a compressible material, such asall rubber, or a composite of a rubber outer plate with a central steelsleeve for mounting to a bar. Some weight plates are also made of solidmetals. Such standardized weight plates typically include a recessedsurface wherein a weight of the plate, such as in pounds (“lb.”),trademarks, logos, design images and/or special event advertising isplaced.

The traditional methods of applying decorative designs, trademarks, etc.to weight plates include screen printing directly to the surface of theplate, painting the plate surface or creating raised lettering duringthe manufacturing process of the plates. In the circumstance of thestandardized rubber weight plates (also known as “bumper plates”), theapplication of the decorative designs is typically done by screenprinting or creating raised rubber letters during the vulcanizationprocess of manufacturing the rubber bumper plates.

Regardless of the manufacturing process, customized application ofdecorative designs, trademarks, etc. is limited due to inefficiency inlow batch quantities of manufacture of the weight plates and istherefore basically cost prohibitive. In addition, application ofdecorative design techniques such as screen printing often isinsufficiently durable for periods of time as well as susceptible todegradation from ultra violet light and chemical exposure which arecommon in weight lifting environments.

Therefore, manufacturers and customers have sought solutions to remedythe aforementioned challenges. One form of modern weight plates hasintegrated a recessed surface on one or both sides of the plate. Asshown in the prior art FIG. 1 of a contemporary weight plate 10, arecessed surface 12 is defined to be essentially co-axial with a centralaxis 13 of the circular plate 10, and markings 14 are located on asupport surface 16 of the recessed surface 12. In the FIG. 1 prior artweight plate 10, the markings are the weight (“35 LB”) of the plate 10.This prevents the markings 14 from being scratched or otherwise damagedduring stacking and/or loading of the weight plates 10 onto each otheror onto a weight bar (not shown). Nonetheless, such use of the recessedsurface 12 still leaves the markings 14 subject to substantial wear andtear. The known methods of placing or defining markings 14 on therecessed surface 12 are quite expensive, especially for limitedproduction of the plates 10 and for a requirement for plates 10 of manydifferent weight markings 14.

Consequently, there is still a need to provide an efficient decorativeassembly and method of use for securing markings such as weights of theplates, custom brand names, branding, decorative designs, trademarks,etc. to weight plates in a cost effective manner at low quantities aswell as in a scale for large batch production. In addition, there is aneed to supply decorative designs to weight plates wherein the designshave adequate durability to resist ultra-violet radiation (“UV”) andchemical exposure as well as wear and tear typical to the weight liftingenvironments.

SUMMARY

The present disclosure is a decorative decal assembly for a weightplate, wherein the weight plate includes a first side and an opposedsecond side, and also includes a recessed surface that is defined withinat least one of the first side and the second side of the plate. Therecessed surface extends between shoulders defined within the side ofthe plate. The shoulders descend below an exterior surface of the sideof the weight plate to surround and thereby define the recessed surface.

The decorative decal assembly includes an adhesive layer that has acontact surface and an opposed support surface. An ink protectingprintable layer has a printable surface that is secured to the supportsurface of the adhesive layer, and the ink protecting printable layeralso has an opposed outer protective surface. At least one ink decal issecured to the printable surface of the ink protecting printable layerso that the ink decal and the printable surface are adjacent and securedto the support surface of the adhesive layer. The recessed surfacedefines a display area surrounded on all sides by an expansion zoneextending between the display area and the shoulders of the weight platethat define the recessed surface. The expansion zone extends asufficient distance between perimeter edges of the display area and theshoulders defining the recessed surface to permit limited expansion ofperimeter edges of the decal assembly into the expansion zone withoutany perimeter edge of the decal assembly contacting the shouldersdefining the recessed surface whenever the weight plate experiences abounce shock. (For purposes herein, the phrase “bounce shock” is to meanthe impact shock experienced by weight plates when at least one weightplate is secured to opposed ends of a horizontal weight bar, and aweight lifter drops the bar from no higher than about ten feet, and theweight plates drop by gravity to a supporting platform to impact theplatform and stop their downward motion. The sudden stop of the weightplates having their display surfaces about vertical to the platformproduces the “bounce shock”.) Additionally, the contact surface of theadhesive layer of the decal assembly contacts, is adhered to andcompletely overlies the display area of the recessed surface. Also, theink protecting printable layer of the decal assembly also completelyoverlies the display area of the recessed surface.

In differing embodiments, the decorative decal assembly may be in aspecific form to match and completely overlie the display area of arecessed surface of a weight plate wherein the recessed surface is inthe form of a co-axial circle, such as for example when the weight plateis circular. The recessed surface may also be in the form of anarbitrarily shaped marking portion of the side of the weight plate.Moreover, the weight plate may include recessed surfaces on both sidesof the plate. Additionally, the components of the decorative decalassembly described in more detail below may include specificformulations varying in form of adhesives, inks, layer substrates,including at least all such components known to be used in applyingmarkings to rubber, plastic or metal surfaces. For example, the “inkdecal” may be a spray or coating of ink onto the printable surface ofthe ink protecting printable layer, such as ink sprayed by a digitalplotter printer, or known “ink-jet” technology; “laser-ink” applicationtechnology, or spread through screen or flexographic printing, etc.

The disclosure also includes methods of forming the decorative decal andapplying it to the recessed surface area of the weight plate.

In further embodiments, the ink decals may be applied, such as by inksprays or coatings, in segments along the printable surface of the inkprotecting printable layer, may be applied to completely overlie theprintable surface including solid ink or clear ink segments betweencolored ink segments, may be applied in several colors in adjacent oroverlapping segments, or may be applied in several colors in stackedoverlying layers including adjacent color segments in the overlyinglayers secured to the printing surface of the ink protecting surfacelayer.

In another embodiment, the expansion zone has an average distancebetween a perimeter edge of the display area and the shoulder of therecessed surface of between about 1 millimeter (“mm”) and 5 mm. (Forpurposes herein the word “about” is to mean plus or minus twentypercent.)

Accordingly, it is a primary purpose of the present disclosure toprovide a decorative decal assembly for a weight plate and a method ofmanufacture of the assembly that overcomes deficiencies of the priorart; that is more durable, less expensive, and easier to make and usethan known production of, and application of, markings on weight plates.These and other advantages purposes of the present disclosure willbecome apparent when the following description is read along with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of prior art weight plate showing acircular recessed surface that is co-axial with a central axis of theweight plate.

FIG. 2 is weight plate having a decorative decal assembly secured withina recessed surface on a side of the weight plate and constructed inaccordance with the present disclosure.

FIG. 3 is a fragmentary, cross-sectional view taken along sight line 3-3of FIG. 2.

DESCRIPTION

Referring to the drawings in detail a decorative decal assembly for aweight plate 18 is shown in FIGS. 2 and 3, and is generally designatedby the reference numeral 20. The weight plate 18 includes a first side22 and an opposed second side 24, and also includes a recessed surface26 that is defined within the first side 22. A second recessed surface28 is defined in the second side 24 of the weight plate 18. The recessedsurface 26 extends between a first shoulder 30 and a second shoulder 32defined within the first side 22 of the plate. The shoulders 30, 32descend below an exterior surface 34 of the first side 22 of the weightplate 18 to surround and thereby define the recessed surface 26.

The decorative decal assembly 20 includes an adhesive layer 36 that hasa contact surface 38 and an opposed support surface 40. The adhesivelayer 36 may be made of a pressure sensitive adhesive such as acrylicadhesive designed for applications requiring clarity, high shear,permanent tack, and chemical resistance. One such permanent acrylicadhesive is Part #TT-V29 from FLEXcon located in Spencer, Mass. orStructured 350 Adhesive from 3M Company which is designed to prevent airbubble formulation when laminated or applied to surfaces. Additionaladhesives include but are not limited to other acrylic,polyurethane-based pressure sensitive adhesives, thermosettingadhesives, epoxy or similar chemical cure adhesives and the like capableof bonding sufficiently to withstand impact and use commonly experiencedby the weight plate.

An ink protecting printable layer 42 has a printable surface 44 that issecured to the support surface 40 of the adhesive layer 36. The inkprotecting printable layer 42 also has an opposed outer protectivesurface 46. The ink protecting printable layer 42 must be made of amaterial capable of withstanding the bounce shock associated with weightplate 18 activity; mechanical stress and deformation experienced by theweight plate 18; resistance to ultra-violet light (“UV” light) and otherchemical exposure; as well as resistant to abrasion. One such materialis a layer 42 of high strength polyurethane film part number EU94DSavailable from Smith and Nephew Extruded Films of East Yorkshire,England. Other comparable materials including polyester, urethane andthermoplastic polyurethane (“TPU”) films, high flex vinyl and comparableprintable films. Experiments by the present inventors have establishedthat the layer 42 should optimally have a thickness that is ideallybetween about 80 microns and about 150 microns thick, which is ofsufficient thickness to withstand abrasive forces experienced by theweight plate. (For purposes herein, the word “thickness” is to mean ashortest distance between opposed outer surfaces of the printablelayer.) For weight plates requiring additional durability and relatedspecific conditions (e.g. exclusively outdoor, ocean-beach usage), theink protecting printable layer 42 may have a thickness between about 50microns to about 300 microns, depending on a predetermined specificapplication for the weight plate 18.

At least one, or a first ink decal 48 is secured to the printablesurface 44 of the ink protecting printable layer 42 so that the inkdecal 48 and the printable surface 44 are adjacent and secured to thesupport surface 40 of the adhesive layer 36. FIG. 3 shows a second inkdecal 50 displaced away from the first ink decal 48; a third ink decal52 similarly displaced away from the second ink decal 50; and, a fourthink decal 54 positioned away from the third ink decal 52. These four inkdecals 48, 50, 52, 54 represent the markings 14 shown in FIG. 2, whereinonly the leading edges of the four ink decals 48, 50, 52, 54 are seen inthe FIG. 3 fragmentary, cross-sectional view taken along sight line 3-3of FIG. 2. By the phrase “ink decal 48”, it is to be understood that theink decal 48 may include a spray of ink 48 onto the printable surface 44of the ink protecting printable layer 42, such as ink sprayed by adigital plotter printer, or “ink-jet” technology; “laser-ink”application technology; chemical etching, screen printing, flexographicprinting or any process known for applying a light-reflective, highlyelastomeric ink substance to the printable surface 44 of the inkprotecting printable layer 42. The ink decal 48 should be curable viaambient conditions or other techniques such as application of UV lightor heat exposure so as to remove any solvent medium, which is oftenwater or volatile, solvent-based compounds. One such ink 48 that may beselected is silkscreen 800 series ink from Union Process of Akron Ohio.It is important to select an ink 48 material which will not fade,discolor or degrade when exposed to conditions such as UV light, heat orother factors and also must be sufficiently elastomeric to withstandmechanical stress and deformation commonly experienced by the weightplate, and identified herein as “bounce shock”.

The recessed surface 26 defines a display area 56 surrounded on allsides by an expansion zone 58 extending between the display area 56 andthe shoulders 30, 32 of the weight plate 18 that define the recessedsurface 26. The expansion zone 58 extends a sufficient distance betweenperimeter edges 60A, 60B of the display area 56 and the shoulders 30, 32defining the recessed surface 26 to permit limited expansion ofperimeter edges 62A, 62B of the decal assembly 20 into the expansionzone 58 without any perimeter edge 62A, 62B of the decal assembly 20contacting the shoulders 30, 32 defining the recessed surface 26whenever the weight plate 18 experiences a bounce shock. Additionally,the contact surface 38 of the adhesive layer of the decal assembly 20contacts, is adhered to and completely overlies the display area 56 ofthe recessed surface. The ink protecting printable layer 42 of the decalassembly 20 also completely overlies the display area 56 of the recessedsurface 26.

It is to be understood that, the decorative decal assembly 20 may be ina specific planar, geometric form to match and completely overlie thedisplay area 56 when the display area takes the shape of a variety offorms. For example, the recessed surface 26 of the weight plate 18 maybe in the shape of a co-axial partial or full circle, such as forexample when the weight plate 18 is circular having a circular outerperimeter, as shown in FIG. 2. The recessed surface 26 may also be inthe form of an arbitrary shape either side 22, 24 of the weight plate18. Moreover, the weight plate 18 may include a plurality of recessedsurfaces 26, 28 on both sides 22, 24 of the plate 18.

In further embodiments, the ink decals 48, 50, 52, 54 may be appliedsuch as by ink sprays or coating, in segments 48, 50, 52, 54 along theprintable surface 44 of the ink protecting printable layer 42. The inkdecals 48, 50, 52, 54, may be applied to completely overlie theprintable surface 44 to also overlie the display area 56 of the recessedsurface 26, including, for example solid ink or clear ink segments (notshown) between colored ink segments 48, 50, 52, 54, that may be appliedin several colors in adjacent or overlapping segments (not shown).Additionally, the ink decals 48, 50, 52, 54 may be applied in severalcolors in stacked overlying layers (not shown) of decals 48, 50, 52, 54,wherein each layer includes adjacent color segments within the overlyinglayers secured to the printing surface 44 of the ink protecting surfacelayer 42. It is to be understood that additional protective layers 42with or without print decals attached thereto (not shown) may be appliedto further protect the ink decals 48, 50, 52, 54, and that thedecorative decal assembly 20 may also include many layers of the inkdecals 48, 50, 52, 54 secured between the printable surface 44 of theink protective printable layer 42 and support layer 40 of the adhesivelayer 36.

In some embodiments, the expansion zone 58 has an average distancebetween a perimeter edge 60A, 60B of the display area 56 and theshoulders 30, 32 of the recessed surface 26 of between about 1millimeter (“mm”) and 5 am. (For purposes herein the word “about” is tomean plus or minus twenty percent.)

The disclosure also includes methods of forming the decorative decalassembly 20 and applying the assembly 20 to the recessed surface area 26of the weight plate 18. An exemplary method includes the steps of firstapplying and securing ink decals 48, 50, 52, 54 to the printable surface44 of the ink protecting printable layer 42; then securing the printablesurface 44 of the layer 42 to the support surface 40 of the adhesivelayer 36; and then securing the contact surface 38 of the adhesive layer36 to the display area 56 of the recessed surface 26. This method mayalso include calibrating ink applicators (not shown) to spay or coat inkdecals 48, 50, 52, 54 within a predetermined area or areas on theprintable surface 44 of the ink protecting printable layer 42 thatcompletely overlie a predetermined area or areas of the display area 56.The method may also include use of standard release liners (not shown)applied to the contact surface 38 of the adhesive layer 36 so that thedecal assembly may be safely stored and transported prior to applicationto the recessed area 26 and the weight plate 18, wherein the releaseliner (not shown) is peeled away from the contact surface 38 of theadhesive layer 36 prior to application of the decal assembly 20 to thedisplay area 56. (It is to be understood that a “release liner” (notshown) is very common in adhesive applications, such as liners pulledaway from U.S. Mail “Express Mail” envelope labels prior to applying theuncovered adhesive on the label to close the envelope. Hence, a “releaseliner” is neither shown in the Figures nor claimed.)

The disclosure also includes the aforesaid methods of forming thedecorative decal assembly 20 and applying it to the recessed surfacearea of the weight plate, along with other known methods of applyinglayered decorative decal assemblies 20 to rubber and/or plasticsurfaces.

While the present disclosure has been presented above with respect tothe described and illustrated embodiments of the decorative decalassembly 20 for a weight plate 21, it is to be understood that thedisclosure is not to be limited to those alternatives and describedembodiments. Accordingly, reference should be made primarily to thefollowing claims rather than the forgoing description to determine thescope of the disclosure.

What is claimed is:
 1. A rubber substrate with decal assembly attachedthereto, wherein the decal assembly comprises: an adhesive layer havinga contact surface that is attached by chemical bond to a surface of therubber substrate; an intermediate layer in direct contact with theadhesive layer, wherein the intermediate layer is formed from anelastomeric material; and a decal on a surface of the intermediate layeropposite the adhesive layer, wherein the decal comprises a coloredmaterial.
 2. The rubber substrate with decal assembly as recited inclaim 1 comprising more than one decals, wherein the decals may be ofone or more colors and/or shapes.
 3. The rubber substrate with decalassembly as recited in claim 1 wherein the decal is disposed on aprintable surface of the intermediate layer.
 4. The rubber substratewith decal assembly as recited in claim 1 wherein the decal is in directcontact with the intermediate layer.
 5. The rubber substrate with decalassembly as recited in claim 1 further comprising a protective layerdisposed over an outer surface of the decal.
 6. The rubber substratewith decal assembly as recited in claim 1 comprising a plurality of thedecals positioned adjacent one another along a display surface of therubber substrate.
 7. The rubber substrate with decal assembly as recitedin claim 1 comprising at least two decals wherein a first decal ispositioned at least partially over a second decal.
 8. The rubbersubstrate with decal assembly as recited in claim 1 comprising more thanone decals, and wherein at least one of the one or more decals comprisesa color different from that of the substrate.
 9. A rubber substrate anddecal assembly comprising; an adhesive layer having a contact surfacethat is attached to a surface of the rubber substrate and having asupport surface opposite the contact surface, wherein the adhesive isformed from a material that chemically bonds to the surface of therubber substrate; an intervening layer in direct contact with theadhesive layer support surface and formed from an elastomeric material;and a visual display on a surface of the intervening layer opposite theadhesive layer, wherein the visual display comprises a colored material.10. The rubber substrate and decal assembly as recited in claim 9wherein the visual display is positioned along a display area of therubber substrate.
 11. The rubber substrate and decal assembly as recitedin claim 10 wherein the display area is a sidewall surface of the rubbersubstrate.
 12. The rubber substrate and decal assembly as recited inclaim 9 comprising two or more visual displays that include at least oneoverlapping segment with one another.
 13. The rubber substrate and decalassembly as recited in claim 9 wherein the intervening layer protectsthe visual display from mechanical stress and deformation associated ofthe substrate.
 14. The rubber substrate and decal assembly as recited inclaim 9 further comprising an outermost layer that is disposed over thevisual display.
 15. The rubber substrate and decal assembly as recitedin claim 9 wherein the decal assembly comprises a number of visualdisplays that are positioned a distance away from one another along thesurface of the rubber substrate.